Methods and apparatus for suspension adjustment

ABSTRACT

A shock absorber includes a gas spring cylinder containing a piston moveable between an extended position and a compressed position within the gas spring cylinder. A mechanical actuator is arranged whereby a bleed port is automatically closed when the gas spring is compressed to a predetermined position corresponding to a desired sag setting. In one embodiment, the position corresponds to a predetermined sag setting whereby the gas spring is partially compressed. In another embodiment, a proper sag setting is determined through the use of a processor and sensor that in one instance measure a position of shock absorber components to dictate a proper sag setting and in another instance calculate a pressure corresponding to a preferred sag setting.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of and claims the benefitof co-pending U.S. patent application Ser. No. 16/201,816, filed on Nov.27, 2018, entitled “METHODS AND APPARATUS FOR SUSPENSION ADJUSTMENT” byGalasso et al., assigned to the assignee of the present application,having Attorney Docket No. FOX-0053US.DIV.CON3, and is herebyincorporated by reference in its entirety herein.

The application Ser. No. 16/201,816 is a continuation application of andclaims the benefit of U.S. patent application Ser. No. 15/211,670, filedon Jul. 15, 2016, now Issued U.S. Pat. No. 10,145,435, entitled “METHODSAND APPARATUS FOR SUSPENSION ADJUSTMENT” by Galasso et al., assigned tothe assignee of the present application, having Attorney Docket No.FOX-0053US.DIV.CON2, and is hereby incorporated by reference in itsentirety herein.

The application Ser. No. 15/211,670 is a continuation application of andclaims the benefit of U.S. patent application Ser. No. 14/940,839, filedon Nov. 13, 2015, now Issued U.S. Pat. No. 9,523,406, entitled “METHODSAND APPARATUS FOR SUSPENSION ADJUSTMENT” by Galasso et al., assigned tothe assignee of the present application, having Attorney Docket No.FOX-0053US.DIV.CON, and is hereby incorporated by reference in itsentirety herein.

The application Ser. No. 14/940,839 is a continuation application of andclaims the benefit of U.S. patent application Ser. No. 14/569,419, filedon Dec. 12, 2014, now Issued U.S. Pat. No. 9,186,949, entitled “METHODSAND APPARATUS FOR SUSPENSION ADJUSTMENT” by Galasso et al., assigned tothe assignee of the present application, having Attorney Docket No.FOX-0053US.DIV, and is hereby incorporated by reference in its entiretyherein.

The application Ser. No. 14/569,419 is a divisional application of andclaims the benefit of U.S. patent application Ser. No. 13/338,047, filedon Dec. 27, 2011, now Issued U.S. Pat. No. 8,936,139, entitled “METHODSAND APPARATUS FOR SUSPENSION ADJUSTMENT” by Galasso et al., assigned tothe assignee of the present application, having Attorney Docket No.FOXF/0053USP1, and is hereby incorporated by reference in its entiretyherein.

The Ser. No. 13/338,047 application claims benefit of U.S. ProvisionalPatent Application Ser. No. 61/427,438, filed Dec. 27, 2010, and claimsbenefit of U.S. Provisional Patent Application Ser. No. 61/533,712,filed Sep. 12, 2011, both of which are herein incorporated by referencein their entireties.

The Ser. No. 13/338,047 application is also a continuation-in-part ofU.S. patent application Ser. No. 13/292,949, filed Nov. 9, 2011, whichclaims benefit of U.S. Provisional Patent Application Ser. No.61/411,901, filed Nov. 9, 2010, both of which are herein incorporated byreference in their entireties.

The Ser. No. 13/338,047 application is also a continuation-in-part ofU.S. patent application Ser. No. 13/022,346, filed Feb. 7, 2011, nowIssued U.S. Pat. No. 10,036,443, which claims benefit of U.S.Provisional Patent Application Ser. No. 61/302,070, filed Feb. 5, 2010,both of which are herein incorporated by reference in their entireties.

The Ser. No. 13/338,047 application is also a continuation-in-part ofU.S. patent application Ser. No. 12/773,671, filed May 4, 2010, whichclaims the benefit of U.S. Provisional Application Ser. No. 61/175,422,filed May 4, 2009, both of which are herein incorporated by reference intheir entireties.

The Ser. No. 13/338,047 application is also a continuation-in-part ofU.S. patent application Ser. No. 12/727,915, filed Mar. 19, 2010, nowIssued U.S. Pat. No. 9,140,325, which claims benefit of U.S. ProvisionalPatent Application Ser. No. 61/161,552, filed Mar. 19, 2009, and U.S.Provisional Patent Application Ser. No. 61/161,620, filed Mar. 19, 2009,each of which are herein incorporated by reference in their entireties.

This patent application is related to U.S. patent application Ser. No.12/773,671; U.S. Provisional Patent Application Ser. No. 61/175,422(“422”); U.S. Provisional Patent Application Ser. No. 61/302,070; andU.S. Provisional Patent Application Ser. No. 61/411,901; each of whichis entirely incorporated herein by reference. Any individual feature orcombination of the features disclosed in the foregoing incorporatedreferences may be suitable for combination with embodiments of thispresent disclosure.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates generally to vehicle suspensions and, morespecifically, to methods and apparatus for suspension adjustment.

Description of the Related Art

Vehicle suspension systems typically include some form of a shockabsorber. Many integrated damper/spring shock absorbers include a damperbody surrounded by a mechanical spring. The damper body often consistsof a vented piston and a shaft telescopically mounted in a fluidcylinder. Some shock absorbers utilize gas as a spring medium in placeof, or in addition to, a mechanical spring. The spring rate of suchshock absorbers may be adjustable such as by adjusting the preload of amechanical spring or adjusting the pressure of the gas in the shockabsorber. In that way the shock absorber can be adjusted to accommodateheavier or lighter carried weight, or greater or lesser anticipatedimpact loads. In vehicle applications, including motorcycles, bicycles,and, particularly, off-road applications, shock absorbers arepre-adjusted to account for varying terrain and anticipated speeds andjumps. Shocks are also adjusted according to certain rider preferences(e.g. soft-firm).

One disadvantage with conventional shock absorbers is that adjusting thespring mechanism to the correct preset may be difficult. The vehiclemust be properly loaded for the expected riding conditions such as witha rider or driver sitting on or in the vehicle while the springmechanism is adjusted to create a proper amount of preload. Often timessuch adjustment requires both a rider sitting on the vehicle and aseparate mechanic performing the proper adjustment at the location ofthe shock absorber. A further disadvantage is that many current systemsrely on imprecise tools and methods to set the initial amount ofpreload.

As the foregoing illustrates, what is needed in the art are improvedapparatus and techniques for easily and accurately adjusting the amountof preload applied to a spring in a shock absorber.

SUMMARY OF THE INVENTION

One embodiment of the present disclosure sets forth a shock absorberthat includes a gas spring cylinder containing a piston. The piston ismoveable between an extended position and a compressed position withinthe gas spring cylinder. A fill port is fluidly coupled to the cylinderand configured to enable gas to be added to the cylinder, and, inaddition, a bleed port is provided to bleed a predetermined amount ofgas from the cylinder. A mechanical actuator is arranged whereby thebleed port is automatically closed when the gas spring is compressed toa predetermined position corresponding to a desired sag setting. Anotherembodiment sets forth a vehicle suspension system that includes theshock absorber discussed above. The vehicle suspension system may alsoinclude a front bicycle or motorcycle (for example) fork incorporatingthe described elements of the shock absorber.

Yet another embodiment sets forth a method for adjusting a vehiclesuspension. The method includes the steps of pressurizing a gas springcylinder of a shock absorber, loading the vehicle suspension with anexpected operating load, bleeding air from the cylinder through a bleedport/valve until a first portion of the suspension reaches apredetermined position relative to another portion of the suspension.The position corresponds to a predetermined sag setting whereby the gasspring is partially compressed.

In yet another embodiment, a proper sag setting is determined throughthe use of a processor and sensor that in one instance measure aposition of shock absorber components to dictate a proper sag settingand in another instance calculate a pressure corresponding to apreferred sag setting.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a gas spring shock absorber;

FIG. 2 is a side view of a shock absorber assembly including a handoperated air pump for use with a gas spring portion of the shock;

FIG. 3A is a sectional side view of a bleed valve in an open positionand 3B illustrates the valve of 3A in a closed position;

FIGS. 4A and 4B are views of a bleed valve bracket for retaining a bleedvalve in a position relative to the shock absorber. FIG. 4A illustratesa retention member in a closed position while 4B illustrates the memberin an open position;

FIG. 5A is a sectional side view of a bleed valve in an open positionand 5B illustrates the valve of 5A in a closed position;

FIG. 6A is a sectional side view of a bleed valve in an open positionand 6B illustrates the valve of 6A in a closed position;

FIG. 7A is a sectional side view of a bleed valve in a closed positionand 7B illustrates the valve of 7A in an open position; and

FIG. 8 is a schematic diagram showing a system.

DETAILED DESCRIPTION

Integrated damper/spring vehicle shock absorbers often include a damperbody surrounded by a mechanical spring. The damper often consists of apiston and shaft telescopically mounted in a fluid filled cylinder. Themechanical spring may be a helically wound spring that surrounds thedamper body. Various integrated shock absorber configurations aredescribed in U.S. Pat. Nos. 5,044,614; 5,803,443; 5,553,836; and7,293,764; each of which is herein incorporated, in its entirety, byreference.

Some shock absorbers utilize gas as a spring medium in place of, or inaddition to, mechanical springs. Gas spring type shock absorbers, havingintegral dampers, are described in U.S. Pat. Nos. 6,135,434; 6,360,857and 6,311,962; each of which is herein incorporated, in its entirety, byreference. U.S. Pat. No. 6,360,857 shows a shock absorber havingselectively adjustable damping characteristics. U.S. Pat. No. 7,163,222,which is incorporated herein, in its entirety, by reference, describes agas sprung front shock absorber for a bicycle (a “fork”) having aselective “lock out” and adjustable “blow off” function.

The spring mechanism (gas or mechanical) of some shock absorbers isadjustable so that it can be preset to varying initial states ofcompression. In some instances the shock spring (gas or mechanical) maycomprise different stages having varying spring rates, thereby givingthe overall shock absorber a compound spring rate depending varyingthrough the stroke length. In that way the shock absorber can beadjusted to accommodate heavier or lighter carried weight, or greater orlesser anticipated impact loads. In vehicle applications includingmotorcycle and bicycle applications and particularly off-roadapplications, shock absorbers are pre-adjusted to account for varyingterrain and anticipated speeds and jumps. Shocks are also adjustedaccording to certain rider preferences (e.g. soft-firm).

A representative embodiment of a shock absorber derives from amodification, as disclosed herein, of the shock absorber shown in FIG.28 of, and elsewhere in, U.S. Pat. No. 7,374,028 (the “028” patent)which is incorporated herein by reference. The term “negative spring” or“negative biasing element” may be better understood by reference to U.S.Pat. Nos. 6,135,434; 6,311,962; and/or 6,105,988; each of which isentirely incorporated herein by reference.

It is noted that embodiments herein of shock absorber adjustment systemsand methods are equally applicable to a vehicle's (such as bicycle ormotorcycle) front forks. Further, it is contemplated that such a bicycleor motorcycle may include both shock absorber and fork, both of whichbenefiting from some or all of the features disclosed herein.

An important initial setting to get correct is suspension “sag.”Suspension sag is the measured distance a shock compresses while therider, wearing intended riding gear, is seated on (for example) abicycle or motorcycle in a riding position, versus its fully extendedposition (sag also applies to ATVs, trucks and other suspension equippedvehicles and may account for not only the driver weight but otheroperational payload weight as well). Getting the sag correct sets thefront end steering/handling geometry, puts the rear suspension at itsintended linkage articulation for pedaling or riding efficiency (ifapplicable) and bump absorption and provides some initial suspensioncompression to allow the wheels/suspension to react to negative terrainfeatures (e.g. dips requiring suspension extension) without having theentire vehicle “fall” into those features. Proper sag adjustment iscritical in ensuring continuous contact between tire and ground andgreatly enhances traction over varied terrain. Often any attention thatis paid to this initial sag setting is focused on the rear suspension,especially in motorcycle applications, but making sure that both thefront and rear sag settings are correct are equally important. In oneembodiment each suspension component is equipped with a position sensor(e.g. electronic or mechanical) for indicating the magnitude (or state)of extension or compression existing in the suspension. In oneembodiment such state of extension or compression is determined bycalculation based on a related parameter of the suspension.

A negative spring is used in conjunction with a primary gas spring tocreate a force equilibrium at zero stroke. If a gas spring is used withno negative spring, the static gas spring force will have to be overcomebefore the fork or shock will move. For a 1 in 2 piston area and a 100psi charged gas spring (and including seal break away force), it wouldtake significantly more than 100 lbs of force to get the fork or shockto begin to move. Such high initial force requirement results in afairly harsh suspension. A negative spring pulls the initial force tomove the fork or shock down to, or close to zero. This effect can alsobe calculated depending on whether the negative spring is a gas springitself, or a coil spring.

U.S. Pat. No. 6,135,434 (“434 patent”), which is entirely incorporatedherein by reference, discloses (see FIGS. 3, 4 and 5 and descriptionsthereof) an integral gas spring and damper type shock absorber includinga negative gas spring 64 and a bypass port or channel 66. As describedin the '434 patent, the axial location of the bypass channel isimportant in properly setting the negative spring pressure versus themain gas spring pressure throughout the shock stroke.

FIG. 1 is a schematic illustration of a gas or “air” spring shockabsorber 100, according to one example embodiment. As shown in FIG. 1 ,the gas spring shock absorber 100 includes a gas cylinder 110 and apiston rod 120 connected to a piston 116 that is telescopically housedwithin the gas cylinder 110. The piston rod 120 passes through a sealedhead 130 of the shock absorber 100. The piston 116 reciprocates in thecylinder body and is sealed against an inner surface of the cylinderbody via a sealing element 118 (e.g., an o-ring) preventing gas from apositive gas spring 142 from flowing into a negative gas spring 144. Asthe piston rod 120 is forced into the gas spring shock absorber 100, thepiston 116 moves into the gas cylinder 110 and compresses the gas in thepositive gas spring 142 thereby resisting the motion of the piston rod120 as the volume of the positive gas spring 142 decreases. Similarly,as the piston rod 120 is extracted from the gas cylinder 110, the piston116 moves towards the sealed head 130 of the gas cylinder 110 andcompresses the negative gas spring 144 resisting motion of the pistonrod 120 as the shock absorber 100 approaches the fully extendedposition.

In one embodiment a shock absorber like the one shown in FIG. 1 may beconnected to a rear linkage of a bicycle (but would normally include anintegral damper as well). In order to charge the positive gas spring142, gas is pumped into the gas cylinder 110 via a fill valve 122. Fillvalve 122 comprises a Schrader type valve such as commonly used withbicycle tubes. Alternatively, fill valve 122 may be some other pneumatictype valve well-known to those of skill in the art. Gas is continuallyadded (e.g., by means of a pump or air compressor) to the gas cylinder110 via fill valve 122 such that the pressure within the positive gasspring 142 increases and forces the piston 116 towards the sealed head130 of the shock absorber 100. Gas is added until the pressure in thepositive gas spring 142 reaches a maximum pressure P1 (e.g., 300 psi)that is one beyond a reasonably anticipated operating pressure but stillbelow any structural pressure limitations of the gas cylinder 110. Fillvalve 122 may then be closed, sealing the gas inside the gas cylinder110. Gas cylinder 110 also includes a bypass channel 112 located a fixeddistance DB from the sealed head 130 of the shock absorber 100. Bypasschannel may be a dimple in the side of gas cylinder 110 configured suchthat when piston 116 is located at the distance DB within the stroke,gas from the positive gas spring 142 may flow freely to the negative gasspring 144, thereby equalizing the pressure on both sides of piston 116.As piston 116 moves below the bypass channel 112, the pressure in thenegative gas spring 144 will be greater than the pressure in thepositive gas spring 142, applying a force on the piston 116 away fromthe sealed head 130 of the shock absorber 100. Conversely, as piston 116moves above the bypass channel 112, the pressure in the negative gasspring 144 will be less than the pressure in the positive gas spring142, applying a force on the piston 116 toward the sealed head 130 ofthe shock absorber 100.

A gas spring typically has a non-linear spring rate because (simplystated and ignoring thermal and other effects) of the ideal gas lawderived principle of P1V1=P2V2 (where P is pressure and V is volume and1 is an initial state and 2 is a second state of a closed system). Avolume change occurs with each increment of linear piston stroke.Increments of V required to effect spring force change get smaller asaxial compression continues as P doubles for every ½V (i.e. ½ reductionof the total remaining volume at any time will double the pressure overthe unreduced remaining volume at the time) change. In other words, each2P change is happening for a constantly decreasing amount of linearstroke hence volume (e.g. logarithmic). This causes an increasing springrate with gas spring compression.

In one embodiment, initial sag can be automatically set and facilitatedby having a position valve attached to the shock absorber such that theposition valve allows main gas spring bleed off to occur until aspecific sag level is achieved at which time the valve is closed. Eachshock absorber has a specific stroke length and proper sag is typicallya predetermined fraction of that stroke. In one embodiment the positionvalve is attached to a fully extended shock absorber such that a plungeror trigger of the valve causes the valve to close at a predetermineddistance into the stroke, under load, from full extension.

In one embodiment, as shown in FIG. 2 , a shock absorber 200 includes adamping body 205 telescopically arranged within a gas spring body 210.Eyelets at an upper 201 and lower 202 ends of the shock absorber permitattachment to separate portions of a vehicle. The shock of FIG. 2 wouldtypically be used at the rear of a bike or other vehicle but theprinciples and embodiments described herein are equally usable withfront suspensions such as front forks. During compression of the shockabsorber 200, the damping body 205 will travel further inside of the gasspring body 210 and hence the exposed length of the damping body willdecrease. In FIG. 2 , the damping body 205 is shown in a fully extendedposition. A hand operated (or automated electric for example) air pump300 includes a hose 306 extending therefrom. A gauge 301 displays themeasurement of pressure delivered by the pump. The hose has a T-junction310 with a first portion connected to a fill valve 215, like a Schradervalve, of the gas spring portion of the shock absorber 200 and a secondend terminates, in one embodiment, at a plunger operated bleed valve 350affixed to a bracket 250. The plunger, as will be disclosed hereinoperates as a “trigger” to shift the bleed valve between an “open” and a“closed” positions. The plunger 305 has an operational axis that issubstantially parallel to the longitudinal axis of the damper body 205and is arranged whereby the valve 350 is open when a plunger 305 mountedat an upper portion thereof is extended and closed when the plunger isdepressed. In one embodiment, the plunger head is directed toward ashoulder 220 of the gas spring body 205 such that sufficient movement ofthe damper body into the gas spring body 210 during shock compressionwill cause the head of the plunger 305 to impact the shoulder 220,thereby depressing the plunger and closing a bleed valve.

In one embodiment shown in FIGS. 2 through 4B, a sag mode valve 325 islocated functionally between an output end of the pump 300 and theplunger operated bleed valve 350. In use, the sag mode valve 325 isclosed when initially pressurizing the gas spring of the shock absorberthrough the fitting 215 (for example to a higher than anticipateddesired operating pressure). Subsequently, the sag mode valve 325 isopened once a rider is seated on a vehicle having the shock absorbermounted thereon, so that the gas spring may bleed off through thenormally open bleed valve 350 until the plunger valve impacts the gasspring body shoulder 220 (see also FIGS. 3A, 3B) thereby stopping thesag bleed process. In use, the bracket 250 is mounted such that theplunger 305 of bleed valve 350 is located a distance from the shoulder220 of the gas spring body 210 corresponding to the desired initial sagtravel (e.g. ¼ or ⅓ of total travel). As air is bled from the gas springthrough the plunger operated bleed valve 350, the damper body 205 movesfurther into the gas spring body 210 until the proper sag distance hasbeen traversed and the plunger operated bleed valve 350 iscorrespondingly closed and the gas spring contains the proper operatingpressure for the given initial load condition. The shock absorber ofFIG. 2 is shown in an extended position and may be mounted to the rearlinkage of a bicycle for operation. FIG. 3A is an enlarged view of theshock absorber of FIG. 2 and shows the plunger operated bleed valve 350in an open position. FIG. 3B illustrates the valve of 3A in a closedposition, the plunger 305 of the plunger operated bleed valve 350 havingbeen depressed by shoulder 220 as the gas spring reaches its preferredsag position. In use, the gas spring is initially pressurized above areasonably anticipated operating pressure through the fill valve (122 ofFIG. 1 and 215 of FIG. 2 ).

One embodiment of the bleed valve bracket 250 is illustrated in FIGS. 4Aand 4B. The bracket is mountable on the damper body 205 due to a hinge252 located on one side thereof and having a latch 254 on an opposingside. A simple fastening member 256 holds the bracket in a circularshape and is used to tighten it around the damper body 205 as shown inFIG. 2 . The plunger operated bleed valve 350 is mounted in a holder 255formed on an exterior of the bracket 250 and positioned so that thebleed valve plunger 305 will be aligned with a shoulder 220 of the gasspring body (FIGS. 3A, 3B). Also visible in the bleed valve holder 225is a retention member 260 that is designed to retain the plunger 305 ofthe plunger operated bleed valve 350 in a depressed or closed positionin order to prevent additional bleed of pressure through the valve 350after a sag position has been established. The retention member 260 isspring biased by spring member 261 and rotatable about an end point 262towards the center of the holder 255 to engage a reduced diameterportion 265 of the plunger 305, thereby preventing the plunger frommoving axially. The plunger 305 itself is not visible in FIGS. 4A, 4Bbut is shown in FIGS. 5A and 5B where the reduced diameter portion 265of the plunger 305 is visible along with the retention member 260 andits position relative to the plunger 305. In FIG. 5A for example, theplunger 305 is in an extended position (plunger operated bleed valveopen) and in FIG. 5B the plunger 305 is in a depressed position (closed)with the retention member 260 seated in the reduced diameter portion 265of the plunger.

In one embodiment, the plunger operated bleed valve 350 may beconfigured as shown in FIGS. 5A and 5B. FIG. 5A shows the valve in a“normally” open position (whereby bleed may occur) with an o-ring 270unseated and the head of plunger 305 extended from valve body. In thisposition, gas pressure within the hose leaks past o-ring 270 and bleedsout through an aperture 272 that controls leak rate. FIG. 5B shows theplunger operated bleed valve 350 in a closed position as would beconsistent with impact of the plunger 305 against a shoulder 220 of agas spring body. In the closed position, the o-ring 270 is seated andthereby seals the gas pressure in the hose from further leakage or bleedthrough the valve 350. As described above, the bleed valve can beretained in the closed position due to the position of the retentionmember 260 relative to the reduced diameter portion 265 as shown in FIG.5B.

In one embodiment, the plunger operated bleed valve 350 may beconfigured as shown in FIGS. 6A and 6B. FIG. 6A shows a plunger 305having a face seal 275 affixed at a lower end. The plunger is held by aspring 276 in a slightly biased manner toward a channel 277 forcompressed gas from hose 306 (not shown). As shown in FIG. 6A, theplunger remains open due to gas pressure against the face seal 275 thatovercomes the bias of the spring 276. Unless the plunger 305 isphysically depressed, gas pressure may leak from the hose valve viaaperture 272 by merely overcoming the force of the spring 276. FIG. 6Bshows the plunger 305 in a depressed position due to contact withshoulder 220 of gas spring body 210 whereby the face seal 275 is sealedagainst an opening of channel 277, thereby blocking pressure bleed fromthe valve 350. As with the embodiment of FIGS. 5A, and 5B, a retentionmember 260 and reduced diameter portion 265 operate to retain the bleedvalve in a closed position, thereby preventing additional gas frombleeding after the preferred sag position has been attained.

FIGS. 7A and 7B show a plunger operated bleed valve 350 utilizing, forexample, a standard Schrader type valve 280 in conjunction with a leverarm 285 that holds a valve stem 281 of the Schrader valve 280 in a down,hence open, position until such time that the arm 285 is levered off ofthe valve stem by an encounter with a shoulder 220 of the gas springbody. The arm 285 is biased by a helical or torsion spring 286 towardthe Schrader valve stem 281 thus toward holding the valve in an openposition to allow bleed pressure to flow from the hose and through thevalve. As shown in FIG. 7B, when the arm 285 is impacted by a shoulder220 of the gas spring body 210, the spring 286 is overcome and theSchrader valve stem 281 is released, thereby closing the valve 350. Alsoshown in FIG. 7B, a cut-out portion 287 of the arm 285 becomes capturedunder a spring steel latch 288 at full sag travel and the Schrader valve280 therefore remains closed until the arm 285 is manually released fromthe latch 288.

In each of the forgoing embodiments, the gas spring part of the shock isinitially pressurized by an external source of air. The air arrives viaan exemplary hand pump 300 but it could be supplied by any powered ormanual type pump, compressor, or even by a portable pre-charged gascartridge. During the initial pressurization of the gas spring, the sagmode valve 325 is closed to override the plunger operated bleed valve350 and prevent operation thereof. Once the pressurization is complete,a rider's weight is placed on (or “in”) the vehicle and the sag modevalve is opened. Thereafter, the bleed valve (which in each case isinitially “open”) permits additional compression of the shock until apredetermined travel point at which a shoulder of one portion of thecompressing shock interferes with a valve member and closes the bleedvalve, thereby stopping the compression travel at a predetermined sagpoint. At this point, the bleed valve will typically be locked out usinga retention member or second valve similar to the ones disclosed inrelation to the embodiments described.

In one embodiment, a preferable initial gas spring pressure P1 isdetermined by loading the air spring with a rider's weight (and/or otherpayload weight) and measuring the pressure developed in the gas springin its loaded state. Assuming the gas spring has a constant piston areathrough the relevant portion of its travel (e.g. extended and loaded)that “loaded” pressure will correspond to the sag pressure because it isthe pressure at which the gas spring balances the operational load.Thereafter, using a (computer) processor and a variation of gas lawequation such as PiVi=PsVs, (where “i” is initial and “s” is sag) aninitial pressure Pi can be calculated that will result in the sagpressure being reached at a desired axial location along the stroke ofthe shock. In one embodiment for example a proper sag compression strokesetting may be in the range of 20-25% of the total available suspensionstroke. In this embodiment, an initial sag position is determined byplacing a rider on (or “in”) the vehicle under a static condition andpermitting the shock to compress. That pressure will be Psag (even ifcompression is complete at a less than desirable location along thestroke of the shock). Once Psag and a desired “sag fraction” (sagportion of the total available stroke) are known, along with the initialvolume and volume per incremental length of the gas spring, an initialpressure requirement Pi can be calculated to result in that sag fractionusing (from Pi=Ps×Vs/Vi) the formula: Pi=Psag×(1-sag fraction). If forexample, desired sag fraction is ¼ or 25% and Psag is measured at 200psi, the equation becomes: Pi=200×(1-0.25). The calculation results in aPi of 150 psi.

In practice, the forgoing operation of determining Pi may be performedin these steps:

1) The shock absorber physical dimensions (e.g. gas spring internaldiameters and axial travel limits) are stored and parameters specific tothe given gas spring are calculated including extended (full stroke out)gas spring volume and volume per incremental axial stroke.

2) The gas spring is initially pressurized at least high enough to avoida bottom out condition it is loaded with a rider's weight but preferablyhigher not exceed maximum operating pressure;

3) with a rider or operational load on the vehicle (e.g. bike), Psag ismeasured to establish the pressure equilibrium based upon, among otherfactors, the rider's weight;

4) (optional) The desired sag fraction may be used in conjunction withcalculated volume per incremental stroke to calculate a sag volume Vscorresponding to the desired sag stroke fraction.

5) with the ideal sag fraction known (e.g. as desired by the user orrecommended by manufacturer), the initial pressure is calculated usingthe formula P1=Psag×1-sag fraction expressed as portion of axial stroketaken up by sag).

6) thereafter, the air shock is inflated to pressure Pi.

In one version of the forgoing embodiment, an automated pump isconnected to the shock absorber main spring fitting and total sprungweight (including rider) is applied to the vehicle. The pump measuresthe equilibrium pressure Psag and then calculates a proper initial shockspring pressure generally from the formula Pi=Psag×[1-sag fraction]. Thepump, by means of for example a screen type display, shows the user thesuggested value for Pi initial and the user then uses the pump tocorrespondingly adjust the pressure state of the uncompressed shockabsorber (after the rider has dismounted). In one embodiment, the pumpautomatically adjusts the uncompressed shock pressure (followingdismount of the rider) by automatically operating (all the whileconnected to a gas input of the gas spring) until the gas springcontains the calculated Pi as measured by the pump. In one embodimentthe pump is equipped with control buttons or a touch screen havingpress-able icons signaling the pump (when appropriately depressed by theuser) that the shock is fully extended, in an equilibrium sag state, orother suitable condition. In one embodiment the pump communicates (e.g.Bluetooth, ANT Plus) information to a “smart phone” or other personaldigital assistant or laptop or pad and the screen of such device acts asthe user interface. In one embodiment the screen prompts the user to:connect the pump to the gas spring; pump the gas spring to overpressure;and load the vehicle, following which the screen displays the sagpressure and then instructs the user to adjust unloaded air pressure toPi (a suggested value is displayed).

In one embodiment an optical sensor can be used to aid in setting sag.For example a digital camera such as that found on a cell phone, inconjunction with the use of the computing power of the cell phone, maybe used. For example, there are a number of currently availableapplications (iPhoto Measurement, for example) for “smart phones” thatpermit measurements to be calculated from two digital images of the sameobject. The ideal gas derivate PiVi=PsagVsag applies. In the case of acamera (e.g. on a phone), a digital image is taken and stored, of theshock in a fully extended position and a second digital image is takenand stored, of the shock subject to full sprung load (e.g. rider) orDsag (“sag distance”). The camera is also equipped to read an opticalidentification and/or data code (or RFID tag) on the suspension andfollowing that access, either from a website or internal memory thephysical characteristics of the suspension including relevant gas springdimensions. The camera is programmed to analyze the two images, takenfrom substantially the same perspective, geometrically and calculate thestroke distance assumed between fully extended “Di” and partiallycompressed “Dsag” positions. The ratio of Vsag/Vi is equal to the ratioDsag/Di and therefore the ideal gas equation may be expressed asPiDi=PsagDsag. For purposes of an optical embodiment, a known initialpressure Pik must be used but the value is not overly important so longas the observed sag position is not a bottomed out position. With Pikknown (as input by the user) and Dsag known (as calculated by thecamera), the camera/phone can calculate (using the ideal gas law) a Psagthat corresponds to the sprung load and observed sag state. That Psagcan then be used in the equation Pi=Psag×1-sag fraction] to determine apreferred Pi. That Pi is then displayed by the user interface of thecamera or camera/phone.

In use the optical embodiment is performed as follows:

1) Data including initial pressure Pik of the gas spring is input intothe phone.

2) The phone may query the suspension for an identifying code and mayplace corresponding suspension data in memory.

3) Using an optical recording device an image is taken of the extendedposition of the gas spring, Di.

4) The spring is then “loaded” and another image is recorded toestablish Dsag.

5) A computer processor calculates the difference between Di and Dsag.

6) Using a known Pik, the processor calculates a Psag.

7) The formula Pi=Psag×[1-sag fraction] is then used to determine a Pithat will result in a preferred Psag.

It is noted that a negative gas spring influence can be calculated alsousing ideal gas law derivative P1V1=P2V2. The initial volume V1 of thenegative spring is known as is the volume of the negative spring at sagV2. In one embodiment an iterative solution can be calculated bysubstituting the foregoing calculated Pi for P1 and solving for P2. Theeffect of P2 can then be added (based on the negative spring piston areaversus the main spring piston area) into the calculation to determinethe Psag offset due to the negative spring. A factor such as 10% can bechosen as a delimiter whereby if the effect is greater than thedelimiter, the pump computer can recalculate Pi accounting for theeffect.

In another embodiment a method of determining a preferred sag can beperformed as follows:

1) Hook up pump;

2) set initial shock pressure to a recommended set pressure to establish“datum”. In one embodiment, recommended initial pressure will beprovided as roughly correlated with rider weight. In the case of a“smart” pump, the information could be stored in the pump processor orsimply looked up in a manual that is provided with the suspensionsystem. In yet another embodiment, the information can be “stored” on adecal code or RFID tag located on the shock and readable by a smartphone or other intelligent device. In other instances, an internet linkis provided on the decal and takes a user to a site with a pagespecifically for product set up and details. In one embodiment,identification codes can be scanned that specify details includingperformance specifications of the suspension components, like gassprings. In one embodiment, the codes and/or data are included on a chipembedded in the suspension. In one embodiment, the chip is an active orpassive radio frequency identification (“RFID”) (optionally includingdata) chip. In one embodiment, the smart pump detects the chip and basedon the data received, proceeds to determine appropriate sag settings.

3) the pump then audibly or visually tells the rider to take the nextstep or the rider inputs by some means to the pump that the set pressureis achieved;

4) thereafter, the rider sits, in normal rider position, on the bike andgoes through proper sag protocol. The rider may bounce on fork/shock andallow to settle while in normal riding position, etc.;

5) the rider then waits in normal riding position until pump providesaudible or visual feedback that it is done taking its measurement. Therider can then dismount;

6) the pump compares Pi to pressure developed under load while rider wasin sag position on the bike and calculates a pressure delta; and

7) the pump then compares the pressure delta to stored information aboutthe gas spring and predicts/calculates what travel the spring saggedinto when the rider was in the normal riding position.

Questions/queries that are determined by the computer/processor include:

1) Did spring sag to ideal (requires+1-tolerance) sag percentage?

If “Yes”=pump communicates to rider that the sag is correct and riderremoves pump.

If “No” because there is too little sag, the pump predicts correctedpressure (lower) to achieve ideal sag for the gas spring and the ridermanually bleeds air pressure to the pressure communicated by the pump.Thereafter, the rider disconnects the pump.

If “No” because due to too much sag, the pump communicates a correctedpressure (higher) to achieve ideal sag and the rider manually raises thepressure to the correct value and thereafter, disconnects the pump.

The directly preceding steps and associated apparatus may be used inwhole or in part and any suitable combination and further in anysuitable combination with any other steps or apparatus included herein.

Proper rebound damping setting often depends on initial spring stiffness(i.e. load) and the spring rate. For example, a higher spring forceusually indicates an increase in desired rebound damping to control thereturn rate of the shock to extension under the force of the spring.When the spring force is lower, a lower rebound damping rate (e.g.force) will be all that is required. The processes described hereinultimately (among other things) result in a properly adjusted initialspring pressure and corresponding spring rate. Because in one embodimentthe pump computer has all of the compression spring and sag data it isalso, based on the particular suspension model, well equipped tocalculate a suggested rebound damping setting corresponding to thepreferred initial spring pressure setting. Additionally the pump will“know” (have stored) what product model (by user input or sensor query)it is operating with and will have access to a correlated table forrebound settings versus initial spring pressure and/or final/proper sag.Therefore, in one embodiment, before the rider removes the pump from thegas spring as described, the pump will also communicate (e.g. display) aproper rebound setting (e.g. the number of clicks on a setting dial forproper rebound dampening. In one embodiment the user is directed,following adjustment of the gas spring to proper initial pressure (e.g.from foregoing sag calculations) to “bounce” (cyclically load) thesuspension several times. Using a sensor for velocity measurement (ormeasuring dynamic pressure within the gas spring and calculatingvelocity based on pressure/volume relationships) the pump or othercomputing device calculates a rebound velocity occurring during thebouncing and determines whether that velocity is too high or too low forexample by comparison with suggested rebound velocities for the givensuspension (which was determined by query or input). The device (or userinterface such as phone) then, if needed because rebound is incorrect,prompts the user to adjust the rebound adjuster in a certain directionhigher or lower such as a dial a certain distance such as for examplenumber of indexing marks or audible clicks.

In addition to rebound dampening, it is also possible for forks orshocks that have adjustable compression damping to make a compressiondamping adjustment based on final gas spring pressure. This can includeanother internal computer “look up” table for compression dampingsetting and final pressure. For example, knowing a weight range of arider from the prior calculations and knowing if the rider added orsubtract air pressure to arrive at a proper sag, the weight of the ridercan be predicted and a corresponding suggested compression dampingadjustment can be made. In a typical example, a heavier rider wouldrequire an increased compression damping setting.

The systems disclosed herein can be fully automatic. If, during the sagsetting process for example, the sag is determined to be not greatenough (stroke), the pump can be constructed, using for example sensorsconnected to a controller in turn connected to servo operated valve orvalves, to bleed itself down to the proper pressure/sag setting. If thishappens dynamically while the rider is on the bike, the bleed mechanismwould be very sophisticated (in terms of measuring air exiting the gasspring) in order to “understand” how much (volume of) air it wasbleeding off so that it could continue its calculations from a knownstarting point (i.e. extended gas volume) without excess error. In oneembodiment the rider can be instructed by the pump to get off the bikefollowing a bleed down, and the pump would sense a “new” initial setpressure again (e.g. Pi), it would then bleed pressure off to what therider would have otherwise done manually above.

If the sag is too much, the pump, in one embodiment being incommunication with a high pressure accumulator/reservoir, would addpressure to the spring to achieve the proper sag. If this is to be donedynamically while the rider is on the bike the pump merely needs to addpressure to find the correct location on the pressure delta versustravel look up table. In one embodiment the rider gets off the bike, andthe pump pressurizes the spring to the appropriate pressure.

FIG. 8 is a schematic view of a system 500 that is primarily electronic.FIG. 8 shows a gas spring along with a hand pump (which couldalternatively be electrically powered) having a pressure sensor 510 anda bleed valve 515 integrated therewith. The pump also includes anelectronic control/processing unit 520 with memory and a user interface525 with controls. Further, the processor 520 is connectable to anothercomputer system (not shown) for programming and/or data download orupload or other suitable operations.

In one embodiment, a shock absorber position sensor/calculator and adata processor (to measure compression of the shock from full extension)is used to help maintain proper sag. The position sensor indicates themagnitude (or state) of extension or compression of a shock absorber(like the one in FIG. 2 ) at any given moment. In one embodiment, asuitable telescopic tube of the shock (like the damper body or the gasspring body, for instance) is equipped or fitted with two piezoelectricsensors. In one embodiment, one of the piezoelectric sensors is a highfrequency exciter which is configured on the tube such that it(substantially) continuously induces impacts to a wall of the tube. Inlay terms, the sensor thumps or pings the tube wall on a continualbasis. In one embodiment, the second piezoelectric sensor is anaccelerometer fixed or configured with the tube wall so as to monitorvibration of the tube wall. In one embodiment, the exciter and themonitor are vibrationally isolated so as not to directly influence eachother. In one embodiment, the frequency of the exciter is intentionallyset well outside any resonant mode of the suspension tube as it travelsthrough its operational suspension stroke. In one embodiment theaccelerometer and “thumper” are calibrated with axial travel of theshock absorber so that measured frequency versus position are known. Inone embodiment, a sensing frequency of the monitor is selected tocoincide (substantially) with at least one resonant mode range of thetube as it travels through its operational stroke. In one embodimentonly one accelerometer is used and it measures the “ringing” frequencyor frequencies (e.g. natural frequency mode or modes) of the shockabsorber as it moves through its travel. The accelerometer has beencalibrated to the shock absorber so that the measured resonance is usedby the processor (compared to axial travel versus resonance data) todetermine axial travel position of the shock absorber.

If the sensor and processor determine that the loaded shock is extendedbeyond a proper sag level, an electrically actuated valve is opened tobleed air pressure from the gas spring in a controlled manner until theproper predetermined sag level is reached, at which point the valveautomatically closes and the pump opts itself out of sag mode. Inanother embodiment, the position sensor/calculator can include a gasspring pressure sensor and a processor that calculates axial shockposition based on the compression ratio of the shock, the pressure ofthe gas spring, and gas compression laws. Likewise, the data processorcan measure compression from full extension or any selectively set“zero” datum.

Alternatively the rider can switch the sag set up mode “off” uponreaching a proper sag setting. In one embodiment, with the pump innormal mode the rider/bike will now be in a proper starting point fortheir sag measurement. When in “pump” mode, more pressure can be addedto the gas spring or pressure can be reduced from the gas spring toaccommodate different rider styles and/or terrain. This auto sag featurecan be achieved electronically as well, by having a shock positionsensor in a computer processor/programming of the pump, and specificshock model data allowing the computer to adjust gas spring preload(e.g. air pressure) appropriately for the given model (in one embodimentas determined by the computer in a query of the shock) what sagmeasurement it should achieve. An electronically controlled pressurerelief valve is utilized to bleed off gas spring pressure until thesensor determines the shock is at its proper sag. The pressure reliefvalve is then directed to close when proper sag is achieved.

One embodiment of the disclosure may be implemented as a program productfor use with a computer system. The program(s) of the program productdefine functions of the embodiments (including the methods describedherein) and can be contained on a variety of computer-readable storagemedia. Illustrative computer-readable storage media include, but are notlimited to: (i) non-writable storage media (e.g., read-only memorydevices within a computer such as compact disc read only memory (CD-ROM)disks readable by a CD-ROM drive, flash memory, read only memory (ROM)chips or any type of solid-state non-volatile semiconductor memory) onwhich information is permanently stored; and (ii) writable storage media(e.g., floppy disks within a diskette drive or hard-disk drive or anytype of solid-state random-access semiconductor memory) on whichalterable information is stored.

In another embodiment, a memory in the ECU or an associated externalmemory includes instructions that cause the processor to perform thecalculations described related to calculating pressures, Pi, Psag, Di,Dsag, etc. In another embodiment, instructions are stored on a servercomputer connected to the internet, the server being configured toreceive the measured values from a client computer, compute thesuggested operational setting, and transmit the suggested operationalsetting to the client computer for display.

The foregoing embodiments while shown in configurations corresponding torear bicycle shock absorbers are equally applicable to bicycle ormotorcycle front forks or other vehicle (e.g. 4 wheel) shock absorbersor other shock absorbers generally having or comprising gas springs orrebound dampers.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be implementedwithout departing from the scope of the invention, and the scope thereofis determined by the claims that follow.

What is claimed is:
 1. A system for a vehicle, the system comprising: a gas spring including a cylinder containing a piston, the piston being moveable between an extended position and a compressed position within the gas spring cylinder; a sensor operable to measure an operational characteristic of the gas spring; and a processor in communication with the sensor and configured to suggest to said system an operational setting of the gas spring in response to an input from the sensor corresponding to the operational characteristic, wherein said sensor is part of a hand-held device such as a smartphone or tablet computer.
 2. The system of claim 1, wherein the processor is configured to determine said operational setting using an equation based on an ideal gas law.
 3. The system of claim 1, wherein the processor is further configured to: receive a value from the sensor that represents a measured operational characteristic of the gas spring at a first state of the gas spring; compute a suggested operational setting of the gas spring in response to receiving the value from the sensor; and cause the suggested operational setting to be output on a user interface.
 4. The system of claim 1 wherein the sensor measures a pressure (Psag) of the gas spring at a point of pressure equilibrium and the processor determines a preferred initial pressure using the formula: Pi=Psag X(1-sag fraction).
 5. The system of claim 1 wherein said gas spring comprises said sensor, and said processor is part of a hand-held computing device separate from, but which can communicate with, the gas spring and sensor.
 6. The system of claim 1, further comprising: a pump operable by the processor to inflate the gas spring.
 7. The system of claim 1, wherein the senor measures a location of gas spring components at an extended position Di and at a sag position Dsag and, using a known initial pressure Pik, the processor determines Psag using the formula: PikDi=PsagDsag and; a preferable sag position is determined using the formula: Pi=Psag X(1-sag fraction).
 8. The system of claim 7, wherein the sensor is an optical device.
 9. A computer-readable medium comprising computer-executable instructions that, when executed, cause a computer to perform the processor steps of claim
 1. 10. A source of pressurized gas, comprising a processor and a memory storing computer executable instructions that, when executed, cause the processor to perform the processor steps of claim
 1. 